Mechanically extensible substrates

ABSTRACT

The present invention is directed to mechanically extensible substrates, and more specifically relates to engineered substrates that exhibit functionality upon application of an external force, which in turn actuates the substrate, optionally releasing an underlying functional agent that assists a specific task or exposing an underlying layer. In accordance with the present invention, the mechanically extensible substrates exhibit a degree of controlled regional disentanglement, an expandable and retractable valve system, a limited degree of rupture, or a combination thereof.

TECHNICAL FIELD

The present invention relates to mechanically extensible substrates, andmore specifically relates to engineered substrates that exhibitfunctionality upon application of an external force, which in turnactuates the substrate, optionally releasing an underlying functionalagent that assists a specific task or exposing a dissimilar underlyingsurface.

BACKGROUND OF THE INVENTION

Nonwoven fabrics and polymeric films are used in a wide variety ofapplications where the engineered qualities of the fabrics and films canbe advantageously employed. The use of selected thermoplastic polymersin the construction of the fibrous and filamentary fabric components,selected treatment of the fibrous or filamentary components (eitherwhile in fibrous form or in an integrated structure), and selected useof various mechanisms by which the fibrous or filamentary components areintegrated into a useful substrate, are typical variables by which toadjust and alter the performance of the resultant nonwoven fabric.

Various substrates, including apertured or non-apertured films, nonwovenstaple fiber substrates, filamentary substrates, and the combinationsthereof, which have been thermally bonded, entangled, or consolidated byother bonding techniques known in the art, have been employed in thedisposable wipes market for performing a specific function. Use ofsingle layer and multi-layered constructs are known in the art, whereinmulti-layered constructs have been known to incorporate a firstsubstrate that exhibits a first performance and a second substrate thatexhibits a second performance.

Disposable wiping substrates are known in the home care market forcleaning hard surfaces, such as kitchen and bathroom counters, sinks,and floors. The personal hygiene market uses hand held disposable wipingsubstrates for facial cleansing, body cleansing, baby wipes, and theapplication of sun screen or insect repellent. Still other disposablewiping substrates are utilized in the automotive industry for applyingcleaning agents to interior car surfaces, the medical industry toadminister disinfectants and antimicrobials, and the industrial industryto dissipate static charge for instance.

In recent years, disposable wiping substrates have been impregnated,submersed, or coated with a functional agent to assist with a specificchore, such as dusting or dish washing. Functional agents are selectedfrom aqueous solutions, powders, and gels that render the substrateready to use directly out of the packaging or after being activated bythe introduction of water. Further, such wiping substrates have beenused in combination with a cleaning implement, such as a mop or handheld duster, wherein various wiping substrates can be affixed to thecleaning implement and discarded after use.

Additional disposable wiping substrate enhancements include imparting athree-dimensional profile into the surface of an otherwise planarsubstrate. A three-dimensional profile is often desired to assist withparticulate capture and entrainment of particulate matter.Three-dimensionality is also often imparted into a substrate foraesthetic purposes only. Aperturing is also utilized alone or incombination with a three-dimensional profile to enhance the performanceor aesthetic quality of a substrate.

The aforementioned substrates are often inextensible, as the end-useproduct didn't necessarily warrant the need for extensibility; however,it has been contemplated that incorporating mechanically activatedextensibility into such substrates may further enhance disposable wipingarticles, as well as other end-use articles including disposableabsorbent hygienic articles, such as feminine hygiene articles, diapers,and incontinence garments. An unmet need exists for extensiblesubstrates that are mechanically actuated, wherein such actuation mayoptionally release a functional agent or expose an underlying surface toenhance the performance or aesthetic nature of the end-use article.

SUMMARY OF THE INVENTION

The present invention is directed to mechanically extensible substrates,and more specifically relates to engineered substrates that exhibitfunctionality upon application of an external force, which in turnactuates the substrate, optionally releasing an underlying functionalagent that assists a specific task or exposing an underlying layer.

In accordance with the present invention, the mechanically extensiblesubstrates exhibit a degree of controlled regional disentanglement, anexpandable and retractable valve system, a limited degree of rupture, ora combination thereof. In one embodiment, the mechanically extensiblesubstrate is an entangled continuous filament nonwoven fabric asdisclosed in co-pending application Ser. No. 09/287,673, herebyincorporated by reference. As disclosed, the entangled filaments areinter-engaged by a matrix of packed continuous complex loops or spirals,with the filaments being substantially free of any breaking, wrapping,knotting, or severe bending. The continuous filament fabric can exhibitcontrolled, regional disentanglement upon extension by varying degreesof inter-engaged loops or spirals so as to create zones of highinter-engaged filaments and low inter-engaged filaments, affecting thebulk and porosity across the fabric. Once the continuous filament fabricis subjected to external forces, the filaments begin to disentangle.Accordingly, the zones of high inter-engaged filaments disentangle lessthan those zones of low inter-engaged filaments. Subsequently, theextensibility of the entangled continuous filament fabric can beregionally controlled.

In another embodiment, the mechanically extensible substrate is anonwoven fabric with a stretch and recovery performance comprising oneor more three-dimensional profile elements. Exemplary fabrics are taughtin U.S. Pat. No. 6,306,234 to Barker, et al., hereby incorporated byreference. In this embodiment, the one or more three-dimensional profileelements imparted in the substrate comprise one or more apertures, whichperform as a regulator system upon extension of the substrate. Suchmechanically extensible substrates can act as a valve between theinterior environment to the exterior environment, or between twointerior environments, or alters the presentation/exposure of anunderlying treated surface.

In yet another embodiment, the mechanically extensible substrate is afilm comprised of a series of weakened points which are predisposed torupture upon exertion of an external force. Similar to those filmsdescribed in U.S. Pat. No. 4,381,326 to Kelly, hereby incorporated byreference, the film of the present invention is produced utilizing“partial depth reticulation”. A film is affected by partial depthreticulation when a film substrate comes in contact with an embossingroll and a smooth roll, wherein the embossing roll preferably isrotating at a slightly higher peripheral speed than the smooth roll.There is a wiping action at the nip which forces a portion of the moltensubstrate into the grooves of the embossing roll imparting weakenedareas into the film substrate. The resultant film can be utilized in alaminate construct where upon mechanical extension of the substrateruptures the weakened areas exposing an underlying surface that mayoptionally be treated with a functional agent.

The aforementioned mechanically extensible substrates are suitable forvarious cleaning and cleansing applications. Such substrates can be usedalone or in combination with existing home care products so as toenhance such products. The mechanically extensible substrates aresuitable either by themselves or in laminate form as cleaning sheets,whereby the substrates can be impregnated or coated with one or morefunctional agents that are activated upon mechanical extension of thesubstrate. Further, the extensible cleaning sheet may have one or morethree-dimensional profiled elements imparted into the substrate surface,thereby creating a foreground surface and background surface. It hasbeen contemplated that such an extensible cleaning sheet may compriseregionally imprinted functional agents, wherein a first functional agentis regionally imprinted on or impregnated into the foreground of thesubstrate and a second functional agent is regionally imprinted orimpregnated into the background of the substrate.

Such mechanically extensible substrates can also be used in combinationwith existing home care products. For instance, the aforementionedextensible substrate may comprise a specific functional agent, such as ableaching agent, and extend over the face of a dish washing wand toassist in removing unsightly stubborn stains caused by tea or coffeefrom porous surfaces, such as sinks and the inside of mugs. In additionto dish washing wands, the mechanically extensible nonwoven substratemay be utilized in combination with mops and brushes, such as toiletbrushes, wherein the substrate extends over the mop or brush to assistin the cleaning process.

The extensible aforementioned substrates are suitable for cleansingapplications as well, such as hygienic face and body cleansing sheets,wherein the extensible sheet may be impregnated or coated with one ormore emollients, organic extracts, vitamins, or other skin wellnessagents. Regionally controlled extensible substrates also benefitcleansing applications due to the exchange of air through the substratewhich promotes lathering to assist with the cleansing process.

It's also in the purview of the present invention to incorporate theextensible substrates as one or more components within disposablehygienic absorbent articles, including, but not limited to feminine careproducts, diapers, and incontinence garments. The extensible substratesmay be utilized, either alone or in laminate form, as topsheets. Suchtopsheets may comprise localized regions of controlled mechanicallyextensibility that release a scent when actuated. Further, theextensible substrates may act as a valve system between the interiorenvironment to the exterior environment of an absorbent article, as wellas cleaning or cleansing applications, or act as a valve system betweentwo interior environments of such applications, or alters thepresentation of such applications by exposing an underlying surface.

Other features and advantages of the present invention will becomereadily apparent from the following detailed description, theaccompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an apparatus suitable for manufacturing amechanically extensible substrate in accordance with the presentinvention;

FIG. 2 is a schematic view of an apparatus suitable for manufacturing amechanically extensible substrate in accordance with the presentinvention;

FIG. 3 is a schematic view of an apparatus suitable for manufacturing amechanically extensible substrate in accordance with the presentinvention;

FIG. 4 a is a diagrammatic view of a mechanically extensible substratemade in accordance with the present invention;

FIG. 4 b is a diagrammatic view of a mechanically extensible substratemade in accordance with the present invention in an extended state;

FIG. 5 a is a diagrammatic view of a mechanically extensible substratemade in accordance with the present invention; and

FIG. 5 b is a diagrammatic view of a mechanically extensible substratemade in accordance with the present invention in an extended state.

DETAILED DESCRIPTION

While the present invention is susceptible of embodiment in variousforms, there is shown in the drawings and will hereinafter be describeda presently preferred embodiment of the invention, with theunderstanding that the present disclosure is to be considered as anexemplification of the invention, and is not intended to limit theinvention to the specific embodiment illustrated.

The present invention is directed to mechanically extensible substratesthat exhibit a degree of controlled regional disentanglement, anexpandable and retractable valve system, a limited degree of rupture, ora combination thereof, upon application of an external force. Mechanicalactuation of the substrates may subsequently result in the release of anunderlying functional agent, such as a cleaning agent or exposure of anunderlying layer.

Substrates

Referring to the drawings, FIG. 1 illustrates an apparatus for themanufacture of a mechanically extensible, entangled continuousfilamentary nonwoven fabric substrate of the invention. Continuousfilaments 2 are melt-extruded, drawn, and then deposited by beam 4 onmoving porous support wire 6 winding on rollers 7 to form an unbondedfilament web 8. As filaments 2 are continuously extruded, they aresubstantially endless. Deposited, unbonded filament web 8 is relativelyfragile, thin, and easily disturbed. Web 8 may be comprised of more thanone layer of filaments 2. The dominant orientation of filaments 2 is inthe machine-direction, with some degree of overlap in thecross-direction. If desired, a variety of techniques may be employed toencourage further separation of individual filaments 2 and greaterrandomness in the cross-direction. These techniques may include, but arenot limited to, impinging filaments 2 with air currents, electrostaticcharging, or contact with solid objects. Also, as is well-known in theart, vacuum may be drawn through support wire 6 in the area ofdepositing filaments 2.

Web 8 is continuously and substantially without interruption advanced topre-entangling station 10 for pre-entanglement with a plurality ofindividual pre-entangling jets 12 that direct water streams of ahydraulic pressure onto web 8. Preferably, pre-entangling station 10comprises from one to four sets of pre-entangling jets 12, with one tothree most preferred. The number of individual jet streams per jet 12will vary with the width of web 8; jet 12 will extend substantiallyacross the width of web 8, with individual jet streams at a density of10 to 50 per inch. The pressures of individual pre-entangling jets 12may vary as desired depending on fabric basis weight.

During pre-entanglement, web 8 is supported on moving support 14, whichmay comprise a forming drum, or as illustrated, a single or dual wiremesh rotating about rollers 15. Because filaments 2 are substantiallyendless and of considerable denier, support 14 need not be of fine meshas may be required for shorter or finer fibers of the prior art. Forhigh pre-entanglement hydraulic pressures associated with heavier basisweight fabrics, supporting web 8 on a rotating forming drum ispreferred. The purpose of pre-entanglement is to create somecohesiveness in web 8 so that web 8 can be transferred and will not bedestroyed by the energy of subsequent high pressure hydroentanglement.After pre-entangling, web 8 is observed to have minimal entanglement andlow strength values.

Subsequently, the continuously moving web 8 is next subjected to highpressure hydroentangling. High pressure hydroentangling may be achievedat a hydro-entanglement station that comprises a plurality of sets ofwater jets 16.

It's also in the purview of the present invention to regionally entanglethe filamentary web. Regionally entangled webs comprise one or morezones that are highly entangled and one or more zones that are less thanhighly entangled or not entangled at all. Achieving zones of variableentanglement within a substrate involve utilizing dissimilar jetpressures from one orifice to the next or preferably not utilizing aselect number of orifices. The resultant substrate can have zones thatexhibit highly inter-engaged loops and spirals, increased bulk, anddecreased porosity, as well as zones that exhibit scarcely inter-engagedloops and spirals, decreased bulk, and increased porosity.

FIG. 2 illustrates an apparatus for the manufacture of a mechanicallyextensible and recoverable substrate comprised of one or morethree-dimensional profile elements imparted into the surface. In thisembodiment, the one or more three-dimensional profile elements impartedin the substrate comprise one or more apertures, which can act as avalve between the interior environment to the exterior environment, orbetween two interior environments, or alters the presentation/exposureof an underlying treated surface.

In accordance with the method disclosed in U.S. Pat. No. 6,306,234,previously incorporated by reference, a precursor web is formedutilizing conventional carding and crosslapping techniques prior tosubjecting the web to hydroentanglement, and a binder application. Thebinder composition, comprising an elastomeric emulsion, may have thefollowing formulation, of or about 0.2% Tween 20 (Wetting Agent), 0.025%Anti-foam Y-30 (Silicone Defoamer), 0.3% of 10% Aqua Ammonia, 0.7% SanCure 861 (Polyurethane), a variable amount of Hystretch V-29 (AcrylicBinder), and water, which can be employed in the bath of the binderapplication station. Tween 20 is commercially available from ICIChemicals, while Antifoam Y-30 is commercially available from DowChemical. Aqua Ammonia is commercially available from Ashland Chemical,while San Cure 861 is available from B.F. Goodrich Company. HystretchV-29 acrylic binder is commercially available from the B.F. GoodrichCompany. This acrylic binder is soft and elastic, and exhibits solventresistance, excellent U.V. stability, dirt resistance, and lowtemperature flexibility.

The aforementioned nonwoven fabric has been particularly configured toexhibit elastic characteristics, that is, extensibility and recovery, inthe cross-direction of the fabric. The cross-direction (CD) istransverse or perpendicular to the machine-direction (MD) of the fabric,that is, the direction in which the fabric is manufactured andprocessed, typically extending along the longitudinal axis of thefabric. By configuring the present fabric to exhibit cross-directionelasticity, the fabric can be employed in those applications in whichsuch elastic characteristics are desirable.

In yet another embodiment, the mechanically extensible substrate is apartial depth reticulated film comprised of a series of weakened pointswhich are predisposed to rupture upon exertion of an external force.Referring to FIG. 3, therein is illustrated an apparatus for forming apartial depth reticulated film. The reticulated film of the invention ispreferably produced by extruding a thin film of a mixture comprising anolefin polymer directly onto a forming apparatus (described below).Conventional extrusion apparatus can be employed. In some cases it hasbeen found that mixing is enhanced by cooling the extruding screw.Extruder screws that are specifically designed for effective mixing areavailable, and may be preferred for efficient commercial operation.

The extruded film is formed into a partial depth reticulated substrate.A preferred way to do this is to form the partial depth reticulatedsubstrate directly from the extruded film without collecting the film asan intermediate product. This can be done by the process which isschematically illustrated in the drawing.

As shown in FIG. 3, a mixture comprising an olefin polymer is extrudedin the form of a thin sheet 12 of molten material through a conventionalslot die 14. The olefin polymer may optionally be combined with staplelength fibers prior to extrusion, wherein the composition of the staplelength fibers are of a higher melt temperature than that of thepolymeric base resin. The still molten substrate 12 is collected on aheated rotating roll 16 having a smooth surface. The heated smooth roll16 has a predetermined peripheral speed. The temperature of the heatedsmooth roll 16 is such that the substrate 12 is molten and formable whenthe substrate 12 reaches the nip 17 between the roll 16 and a secondroll 18. The second (embossing) roll 18 is in contact with the smoothroll 16 at the said nip 17 between the two rolls. The embossing roll 18is cooled, and has a resilient engraved surface. The engraving is in theform of continuous recessed areas 20 surrounding discontinuous raisedareas 21. For instance, a preferred engraved pattern has a first seriesof grooves running circumferentially around the surface of the embossingroll 18, and a second series of grooves running perpendicular to andintersecting the first series of grooves. The said second series ofgrooves are parallel to the longitudinal axis of the embossing roll 18.They are shown in cross-section and exaggerated form as 20 in thedrawings.

The sheet 12 transfers from the smooth roll 16 to the embossing roll 18at the nip 17 between the two rolls. The embossing roll 18 is cooled andpreferably is rotating at a slightly higher peripheral speed than thesmooth roll 16. In some cases, the two rolls 16, 18 can rotate at thesame speed, and in others, the embossing roll 18 can be slightly slowerthan the smooth roll 16. There is a wiping action at the nip 17 whichforces a portion of the molten substrate 12 into the grooves 20, to formlocalized thinned areas throughout the substrate. The sheet begins tosolidify in the form of a partial depth reticulated substrate 22 whileit is in contact with the embossing roll 18. The substrate will have thesame structure or pattern as the engraved grooves on the roll 18. Whenactuated by an external force, the localized thinned areas rupture;however when staple length fibers have been incorporated into the baseresin, the fibers can remain relatively intact.

The aforementioned substrates of the present invention may be combinedwith one or more similar or dissimilar substrates to form a laminateconstruct. Such substrates include, but are not limited to wovens,continuous and discontinuous filamentary nonwovens, carded nonwovens,various films, such as monolithic or microporous films, a supportivemember, such as a spunbond or mesh scrim, or a barrier layer of sorts.Continuous filamentary substrates are manufactured utilizing thespunbond process. A process for the formation of spunbond involvessupplying a molten polymer, which is then extruded under pressurethrough a large number of orifices in a plate known as a spinneret ordie. The resulting continuous filaments are quenched and drawn by any ofa number of methods, such as slot draw systems, attenuator guns, orGodet rolls. The continuous filaments are collected as a loose web upona moving foraminous surface, such as a wire mesh conveyor belt. Whenmore than one spinneret is used in line for the purpose of forming amulti-layered fabric, the subsequent webs is collected upon theuppermost surface of the previously formed web. The web is then at leasttemporarily consolidated, usually by means involving heat and pressure,such as by thermal point bonding. Using this bonding means, the web orlayers of webs are passed between two hot metal rolls, one of which hasan embossed pattern to impart and achieve the desired degree of pointbonding, usually on the order of 10 to 40 percent of the overall surfacearea being so bonded.

A process related to the formation of spunbond is the meltblown process,which involves the formation of discontinuous filaments. Again, a moltenpolymer is extruded under pressure through orifices in a spinneret ordie. High velocity air impinges upon and entrains the filaments as theyexit the die. The energy of this step is such that the formed filamentsare greatly reduced in diameter and are fractured so that microfibers offinite length are produced. This differs from the spunbond processwhereby the continuity of the filaments is preserved. The process toform either a single layer or a multiple-layer fabric is continuous,that is, the process steps are uninterrupted from extrusion of thefilaments to form the first layer until the bonded web is wound into aroll. Methods for producing these types of fabrics are described in U.S.Pat. No. 4,043,203. The meltblown process, as well as thecross-sectional profile of the spunbond filament or meltblownmicrofiber, is not a critical limitation to the practice of the presentinvention.

A nano-fiber of finite or infinite length may also be utilized in thepresent invention, wherein the average fiber diameter of the nano-fiberis in the range of less than or equal to 1000 nanometers, and preferablyless than or equal to 500 nanometers. Formation of substrates fromnano-fibers, particularly when a light basis weight nano-fiber barrierlayer is preferred, is either coated or “dusted” onto a substrate layer.The present invention may utilize a nano-fiber layer of less than about2 grams per square meter.

In addition, one or more of the substrates may be imparted with one ormore surface asperities, such as three-dimensional profiled elements,apertures, or a combination thereof. Three-dimensional profiled elementsmay be imparted into a substrate surface by way of a forming apparatus,wherein the forming surface may be a profiled continuous surface, aplurality of linked profiled plates, and the combinations thereof.Further still, the forming surface may be circular in formation (i.e.drum-like), as well as planar, and follow a pre-determined continuouspath. In one embodiment, the forming surface is such as that describedin U.S. Pat. No. 5,244,711 and No. 5,098,764, and incorporated herein byreference.

Functional Agents

Cleaning compositions suitable for use in the various end-useapplications include those that are described in U.S. Pat. No. 6,103,683to Romano, et al., No. 6,340,663 to Deleo, et al., No. 5,108,642 toAszman, et al., and No. 6,534,472 Arvanitidou, et al., all of which arehereby incorporated by reference. Selected cleaning compositions mayalso include surfactants, such as alkylpolysaccharides, alkylethoxylates, alkyl sulfonates, and mixtures thereof; organic solvent,mono- or polycarboxylic acids, odor control agents, such ascyclodextrin, peroxides, such as benzoyl peroxide, hydrogen peroxide,and mixtures thereof, thickening polymers, aqueous solvent systems, sudssuppressors, perfumes or fragrances, and detergent adjuvants, such asdetergency builder, buffer, preservative, antibacterial agent, colorant,bleaching agents, chelants, enzymes, hydrotropes, and mixtures thereof.The aforementioned compositions preferably comprise from about 50% toabout 500%, preferably from about 200% to about 400% by weight of thedual sided nonwoven cleaning article.

The single or multi-layered extensible substrates embodying theprinciples of the present invention is also suitable for personalcleaning or cleansing articles. Non-limiting examples of suchapplications include dry or wet facial wipes, body wipes, and babywipes. Suitable methods for the application of various aqueous andnon-aqueous compositions comprise aqueous/alcoholic impregnates,including flood coating, spray coating or metered dosing. Further, morespecialized techniques, such as Meyer Rod, floating knife or doctorblade, which are typically used to impregnate cleansing solutions intoabsorbent sheets, may also be used. The following compositionspreferably comprise from about 50% to about 500%, preferably from about200% to about 400% by weight of the dual sided nonwoven article.

The extensible substrates may incorporate an alpha-hydroxycarboxylicacid, which refers not only the acid form but also salts thereof.Typical cationic counterions to form the salt are the alkali metals,alkaline earth metals, ammonium, C₂-C₋₈ trialkanolammonium cation andmixtures thereof. The term “alpha-hydroxycarboxylic acids” include notonly hydroxyacids but also alpha-ketoacids and related compounds ofpolymeric forms of hydroxyacid.

Amounts of the alpha-hydroxycarboxylic acids may range from about 0.01to about 20%, preferably from about 0.1 to about 15%, more preferablyfrom about 1 to about 10%, optimally from about 3 to about 8% by weightof the composition which impregnates the substrate. The amount ofimpregnating composition relative to the substrate may range from about20:1 to 1:20, preferably from 10:1 to about 1:10 and optimally fromabout 2:1 to about 1:2 by weight.

Further, a humectant may be incorporated with the aforementionedalpha-hydroxycarboxylic compositions. Humectants are normally polyols.Representative polyols include glycerin, diglycerin, polyalkyleneglycols and more preferably alkylene polyols and their derivatives.Amounts of the polyol may range from about 0.5 to about 95%, preferablyfrom about 1 to about 50%, more preferably from about 1.5 to 20%,optimally from about 3 to about 10% by weight of the impregnatingcomposition.

A variety of cosmetically acceptable carrier vehicles may be employedalthough the carrier vehicle normally will be water. Amounts of thecarrier vehicle may range from about 0.5 to about 99%, preferably fromabout 1 to about 80%, more preferably from about 50 to about 70%,optimally from about 65 to 75% by weight of the impregnatingcomposition.

Preservatives can desirably be incorporated protect against the growthof potentially harmful microorganisms. Suitable traditionalpreservatives for compositions of this invention are alkyl esters ofpara-hydroxybenzoic acid. Other preservatives which have more recentlycome into use include hydantoin derivatives, propionate salts, and avariety of quatenary ammonium compounds. Preservatives are preferablyemployed in amounts ranging from 0.01% to 2% by weight of thecomposition.

The cosmetic composition may further include herbal extracts.Illustrative extracts include Roman Chamomile, Green Tea, Scullcap,Nettle Root, Swertia Iaponica, Fennel and Aloe Vera extracts. Amount ofeach of the extracts may range from about 0.001 to about 1%, preferablyfrom about 0.01 to about 0.5%, optimally from about 0.05 to about 0.2%by weight of a composition.

Additional cosmetic additives may also include vitamins such as VitaminE Acetate, Vitamin C, Vitamin A Palmitate, Panthenol and any of theVitamin B complexes. Anti-irritant agents may also be present includingthose of steviosides, alpha-bisabolol and glycyhrizzinate salts, eachvitamin or anti-irritant agent being present in amounts ranging fromabout 0.001 to about 1.0%, preferably from about 0.01 to about 0.3% byweight of the composition.

These impregnating compositions of the present invention may involve arange of pH although it is preferred to have a relatively low pH, forinstance, a pH from about 2 to about 6.5, preferably from about 2.5 toabout 4.5.

In addition to cosmetic compositions, lotions may be incorporated intothe extensible substrates. The lotion preferably also comprises one ormore of the following: an effective amount of a preservative, aneffective amount of a humectant, an effective amount of an emollient; aneffective amount of a fragrance, and an effective amount of a fragrancesolubilizer.

As used herein, an emollient is a material that softens, soothes,supples, coats, lubricates, or moisturizes the skin. The term emollientincludes, but is not limited to, conventional lipid materials (e.g.fats, waxes), polar lipids (lipids that have been hydrophylicallymodified to render them more water soluble), silicones, hydrocarbons,and other solvent materials. Emollients useful in the present inventioncan be petroleum based, fatty acid ester type, alkyl ethoxylate type,fatty acid ester ethoxylates, fatty alcohol type, polysiloxane type,mucopolysaccharides, or mixtures thereof.

Humectants are hygroscopic materials that function to draw water intothe stratum corneum to hydrate the skin. The water may come from thedermis or from the atmosphere. Examples of humectants include glycerin,propylene glycol, and phospholipids.

Fragrance components may be utilized, such as perfumes, include, but arenot limited to water insoluble oils, including essential oils. Fragrancesolubilizers are components which reduce the tendency of the waterinsoluble fragrance component to precipitate from the lotion. Examplesof fragrance solubilizers include alcohols such as ethanol, isopropanol,benzyl alcohol, and phenoxyethanol; any high HLB (HLB greater than 13)emulsifier, including but not limited to polysorbate; and highlyethoxylated acids and alcohols.

Preservatives prevent the growth of micro-organisms in the liquid lotionand/or the substrate. Generally, such preservatives are hydrophobic orhydrophilic organic molecules. Suitable preservatives include, but arenot limited to parabens, such as methyl parabens, propyl parabens, andcombinations thereof.

The lotion can also comprise an effective amount of a kerotolytic forproviding the function of encouraging healing of the skin. An especiallypreferred kerotolytic is Allantoin ((2,5-Dioxo-4-Imidazolidinyl)Urea), aheterocyclic organic compound having an empirical formula C₄H₆N₄O₃.Allantoin is commercially available from Tri-K Industries of Emerson,N.J. It is generally known that hyperhydrated skin is more susceptibleto skin disorders, including heat rash, abrasion, pressure marks andskin barrier loss. An extensible substrate according to the presentinvention can include an effective amount of allantoin for encouragingthe healing of skin, such as skin which is over hydrated.

The lotion can further comprise between about 0.1 and about 3 percent byweight Allantoin, and about 0.1 to about 10 percent by weight of an aloeextract, such as aloe vera, which can serve as an emollient. Aloe veraextract is available in the form of a concentrated powder from the RitaCorporation of Woodstock, Ill.

Further, latherants may be incorporated within the single ormulti-layered extensible substrates. Non-limiting examples of anioniclathering surfactants useful in the compositions of the presentinvention are disclosed in McCutcheon's, Detergents and Emulsifiers,North American edition (1986), published by allured PublishingCorporation; McCutcheon's, Functional Materials, North American Edition(1992); and U.S. Pat. No. 3,929,678, to Laughlin et al., issued Dec. 30,1975, all of which are incorporated by reference herein in theirentirety. A wide variety of anionic lathering surfactants are usefulherein. Non-limiting examples of anionic lathering surfactants includethose selected from the group consisting of sarcosinates, sulfates,isethionates, taurates, phosphates, lactylates, glutamates, and mixturesthereof.

Non-limiting examples of nonionic lathering surfactants and amphotericsurfactants for use in the compositions of the present invention aredisclosed in McCutcheon's, Detergents and Emulsifiers, North Americanedition (1986), published by allured Publishing Corporation; andMcCutcheon's, Functional Materials, North American Edition (1992); bothof which are incorporated by reference herein in their entirety.

Non-ionic lathering surfactants useful herein include those selectedfrom the group consisting of alkyl glucosides, alkyl polyglucosides,polyhydroxy fatty acid amides, alkoxylated fatty acid esters, latheringsucrose esters, amine oxides, and mixtures thereof.

The term “amphoteric lathering surfactant,” as used herein, is alsointended to encompass zwitterionic surfactants, which are well known toformulators skilled in the art as a subset of amphoteric surfactant.

A wide variety of amphoteric lathering surfactants can be used in thecompositions of the present invention. Particularly useful are thosewhich are broadly described as derivatives of aliphatic secondary andtertiary amines, preferably wherein the nitrogen is in a cationic state,in which the aliphatic radicals can be straight or branched chain andwherein one of the radicals contains an ionizable water solubilizinggroup, e.g., carboxy, sulfonate, sulfate, phosphate, or phosphonate.Non-limiting examples of amphoteric or zwitterionic surfactants arethose selected from the group consisting of betaines, sultaines,hydroxysultaines, alkyliminoacetates, iminodialkanoates,aminoalkanoates, and mixtures thereof.

Additional compositions utilized in accordance with the presentinvention can comprise a wide range of optional ingredients. The CTFAInternational Cosmetic ingredient Dictionary, Sixth Edition, 1995, whichis incorporated by reference herein in its entirety, describes a widevariety of nonlimiting cosmetic and pharmaceutical ingredients commonlyused in the skin care industry, which are suitable for use in thecompositions of the present invention. Nonlimiting examples offunctional classes of ingredients are described at page 537 of thisreference. Examples of these functional classes include: abrasives,anti-acne agents, anti-caking agents, antioxidants, binders, biologicaladditives, bulking agents, chelating agents, chemical additives,colorants, cosmetic astringents, cosmetic biocides, degreasers,denaturants, drug astringents, emulsifiers, external analgesics, filmformers, fragrance components, humectants, opacifying agents,plasticizers, preservatives, propellants, reducing agents, skinbleaching agents, skin-conditioning agents (emollient, humectants,miscellaneous, and occlusive), skin protectants, solvents, foamboosters, hydrotropes, solubilizing agents, suspending agents(nonsurfactant), sunscreen agents, ultraviolet light absorbers, andviscosity increasing agents (aqueous and nonaqueous). Examples of otherfunctional classes of materials useful herein that are well known to oneof ordinary skill in the art include solubilizing agents, sequestrants,and keratolytics, and the like.

The aforementioned classes of ingredients are incorporated in a safe andeffective amount. The term “safe and effective amount” as used herein,means an amount of an active ingredient high enough to modify thecondition to be treated or to deliver the desired skin benefit, but lowenough to avoid serious side effects, at a reasonable benefit to riskratio within the scope of sound medical judgment.

In addition to home care and personal care end uses, the extensiblesubstrates may be used in industrial and medical applications. Forinstance, the extensible substrates may be useful in paint preparationand cleaning outdoor surfaces, such as lawn furniture, grills, andoutdoor equipment. Aqueous or non-aqueous functional industrial solventswhich may be utilized in the present invention include, oils, such asplant oils, animal oils, terpenoids, silicon oils, mineral oils, whitemineral oils, paraffinic solvents, polybutylenes, polyisobutylenes,polyalphaolefins, and mixtures thereof, toluenes, sequestering agents,corrosion inhibitors, abrasives, petroleum distillates, and thecombinations thereof.

The extensible substrates may incorporate an antimicrobial composition,including, but not limited to iodines, alcohols, such as such as ethanolor propanol, biocides, abrasives, metallic materials, such as metaloxide, metal salt, metal complex, metal alloy or mixtures thereof,bacteriostatic complexes, bactericidal complexs, and the combinationsthereof.

Additional compositions utilized in accordance with the presentinvention can comprise a wide range of optional ingredients. The CTFAInternational Cosmetic ingredient Dictionary, Sixth Edition, 1995, whichis incorporated by reference herein in its entirety, describes a widevariety of nonlimiting cosmetic and pharmaceutical ingredients commonlyused in the skin care industry, which are suitable for use in thecompositions of the present invention. Nonlimiting examples offunctional classes of ingredients are described at page 537 of thisreference. Examples of these functional classes include: abrasives,anti-acne agents, anticaking agents, antioxidants, binders, biologicaladditives, bulking agents, chelating agents, chemical additives, naturaladditives, colorants, cosmetic astringents, cosmetic biocides,degreasers, denaturants, drug astringents, emulsifiers, externalanalgesics, film formers, fragrance components, humectants, opacifyingagents, plasticizers, preservatives, propellants, reducing agents, skinbleaching agents, skin-conditioning agents (emollient, humectants,miscellaneous, and occlusive), skin protectants, solvents, foamboosters, hydrotropes, solubilizing agents, suspending agents(nonsurfactant), sunscreen agents, ultraviolet light absorbers, andviscosity increasing agents (aqueous and nonaqueous). Examples of otherfunctional classes of materials useful herein that are well known to oneof ordinary skill in the art include solubilizing agents, sequestrants,and keratolytics, and the like.

End-Use Applications

The extensible substrates of the present invention are suitable for homeand personal care cleaning and cleansing applications, which can beutilized in the form of a standard hand sheet, glove, mitt, puff, orpad. Such substrates may be used by themselves or in combination with acleaning implement. The extensible substrates are affected by anexternal force by way of disentangling, as shown in FIGS. 4 a and 4 b,stretching, as shown in FIGS. 5 a and 5 b, or rupturing, as shown inFIGS. 6 a and 6 b. The extensible substrates may comprise an internaland/or external functional agent for a specific end-use. Extension ofthe substrates may activate a functional agent or expose an underlyinglayer.

One particular application for the mechanically extensible substrates isa hygienic body wipe when wash water is not available, for example whentraveling. Wipes are commonly used for human cleansing and wiping suchas face and hand cleansing. Wipes may also be used for application ofsubstances to the body including removing and applying of make-up, skinconditioners and medications. Another application of wipes is duringdiaper changes and also for the treatment of adult and baby dermatitispartly caused by the use of diapers and incontinence devices. Inaddition, wipes are also applicable for wiping and or cleaning othersurfaces or for the application of compositions to surfaces, for examplekitchen and bathroom surfaces, eyeglasses, shoes and surfaces whichrequire cleaning in industry for example surfaces of machinery orautomobiles. Wipes also include articles used for the cleaning orgrooming of pets.

The extensible substrates of the present invention are suitable fordisposable absorbent article applications, wherein the mechanicallyextensible substrates may be used as a single or multi-layer topsheet,surge layer, core wrap, core layer, and/or backsheet component of theabsorbent article, such as a sanitary napkin, a panty liner, a pantyshield, diaper, and incontinent garment. The extensible substrates mayact as a valve system between the interior environment to the exteriorenvironment of an absorbent article, as well as cleaning or cleansingapplications, or act as a valve system between two interior environmentsof such applications, or alters the presentation of such applications byexposing an underlying surface.

Additional end-uses include industrial applications, such as single ormulti-layer tapes, tarpaulins, agricultural cover, and car cover.Further, medical applications may benefit from the extensible substratesfor use as bandages, wraps, surgical drapes, and gowns.

From the foregoing, it will be observed that numerous modifications andvariations can be affected without departing from the true spirit andscope of the novel concept of the present invention. It is to beunderstood that no limitation with respect to the specific embodimentsillustrated herein is intended or should be inferred. The disclosure isintended to cover, by the appended claims, all such modifications asfall within the scope of the claims.

1. A method of making a mechanically extensible substrate exhibitingregionally controlled disentanglement upon extension comprising thesteps of: providing a continuous filament substrate; a. providing anentanglement apparatus comprising jets that extend the width of saidsubstrate; b. advancing said substrate onto said apparatus; and c.variably entangling said substrate, whereby one or more jets exhibitdissimilar jet pressures.
 2. A method of making a mechanicallyextensible substrate comprising one or more three-dimensional profiledelements and a stretch and recovery performance comprising the steps of:a. providing a nonwoven web comprising staple length fibers; b.hydroentangling said nonwoven web, wherein said web is imparted with oneor more three-dimensionally profiled elements; and c. applying apolymeric binder composition substantially uniformly to said nonwovenweb, wherein said binder composition comprising between about 17% and31%, by weight, of acrylic binder.
 3. A method of making a mechanicallyextensible partial depth reticulated film substrate with one or morelocalized thin areas prone to rupture upon exerting an external forcecomprising the steps of: a. providing a conventional extrusionapparatus; b. providing a polymeric melt; c. extruding said melt fromsaid apparatus; d. collecting said melt as a formable substrate onto aheated surface; and e. embossing said substrate so as to impartlocalized thinned areas into said substrate.
 4. A method of making amechanically extensible substrate as in any one of the aforementionedclaims, wherein said substrate comprises an internal functional agent,topical functional agent, or a combination thereof.